Space filler with a vacuum cover

ABSTRACT

A vehicle having a space filling panel including a polystyrene layer, a polyurethane layer, and a polyethylene cover where the polyethylene cover forms a vacuum sealed space. The polystyrene layer and the polyurethane layer are both positioned in the polyethylene cover&#39;s vacuum sealed space. In another embodiment, a space filling panel for a vehicle includes a polystyrene layer comprising a plurality of polyurethane chips. The polystyrene layer having the plurality of polyurethane chips is enclosed in a vacuum sealed space formed by a polyethylene cover.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/232,349, filed Aug. 9, 2016, entitled “SPACE FILLER WITH A VACUUMCOVER,” now U.S. Pat. No. 9,849,845, the entirety of which isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to a space filling panel for usein a motor vehicle and, more specifically, to a space filling panel thatoffers improved noise, vibration, and harshness (NVH) performance.

BACKGROUND OF THE INVENTION

Vehicles often have spaces that are left unfilled that require the usageof space fillers. In addition, these unfilled spaces can contribute toan unwanted increase in noise levels. Many space fillers on the marketdo not adequately fill the open spaces in a vehicle, and these spacefillers can often squeak and break apart when placed under the typicalforces experienced in a moving vehicle. The need for a space filler withimproved NVH properties and economical production costs are needed inthe market.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an acousticallyabsorptive space filling panel for a vehicle includes a polystyrenelayer, a polyurethane layer, and a polyethylene cover forming a vacuumsealed space. The polystyrene layer and polyurethane layer arepositioned in the vacuum sealed space.

According to another aspect of the present invention, a space fillingpanel for a vehicle includes a polystyrene layer having a plurality ofpolyurethane chips, and a polyethylene cover forming a vacuum sealedspace. The polystyrene layer having the plurality of polyurethane chipsis positioned in the vacuum sealed space.

According to another aspect of the present invention, a method formaking a space filling panel in a vehicle includes forming a firstlayer, forming a second layer, contacting a first side of the firstlayer with a second side of the second layer, and vacuum sealing thefirst layer and the second layer with a polymeric cover. The spacefilling panel is disposed in a cabin floor of the vehicle.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an isometric back side perspective view of a vehicle accordingto one embodiment;

FIG. 2 is a partially schematic cross-sectional view of a main cabinfloor of a vehicle according to one embodiment;

FIG. 3 is an isometric view of a space filling panel according to oneembodiment;

FIG. 4 is a top view of the space filling panel shown in FIG. 3;

FIGS. 5-5A are partially schematic cross-sectional views of a portion ofthe space filling panel of FIG. 3 taken along the line V-V;

FIG. 6 is a partially schematic fragmentary cross-sectional view of thespace filling panel of FIG. 4 taken along the line VI-VI;

FIG. 7 is a bottom view of the polystyrene layer having a pyramidalsurface geometry and a top view of the polyurethane layer having apyramidal surface geometry according to one embodiment;

FIG. 7A is a side view of the space filling panel made from the layersin FIG. 7 according to one embodiment;

FIG. 8 is a bottom view of the polystyrene layer having a cylindricalsurface geometry and a top view of the polyurethane layer having acylindrical surface geometry according to one embodiment;

FIG. 8A is a side view of the space filling panel made from the layersin FIG. 8 according to one embodiment;

FIG. 9 is a bottom view of the polystyrene layer having a channeledsurface geometry and a top view of the polyurethane layer having achanneled surface geometry according to one embodiment;

FIG. 9A is a side view of the space filling panel made from the layersof FIG. 9 according to one embodiment; and

FIG. 9B is a partially schematic fragmentary cross-sectional view of aportion of the space filling panel in FIG. 9A taken along the lineIXB-IXB.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As used herein, the term “and/or,” wherein used in a list of two or moreitems, means that any one of the listed items can be employed by itself,or any combination of two or more of the listed items can be employed.For example, if a composition is described as containing components A,B, and/or C, the composition can contain A alone; B alone; C alone; Aand B in combination; A and C in combination; B and C in combination; orA, B, and C in combination.

Referring to FIGS. 1-5, and FIGS. 7-9B, reference numeral 10 generallydesignates a vehicle, shown as a wheeled motor vehicle, having a spacefilling panel 14. The space filling panel 14 has a polystyrene layer 18,a polyurethane layer 22, and a polyethylene cover 26 where thepolyethylene cover 26 forms a vacuum sealed space 30. The polystyrenelayer 18 and the polyurethane layer 22 are both positioned in thepolyethylene cover's 26 vacuum sealed space 30.

The space filling panels 14 described herein can be used as alightweight and affordable option to prevent squeaks and reduce thenoise, vibration, and harshness (NVH) experienced by an occupant in thevehicle 10. These space filling panels 14 can be used inside the vehicle10 in spaces that are left unfilled where the polystyrene layer 18,polyurethane layer 22, and polyethylene cover 26 can be designed to fitin any opening or space. The polymer fillers in the vacuum sealed space30 of the polyethylene cover 26 can also be used to give structuralsupport to features in the vehicle 10 for both comfort and appearance tothe occupant.

Referring now to FIG. 1, the vehicle 10 has a main cabin 34 configuredto accommodate one or more passengers and a main cabin floor 38. Themain cabin floor 38 may have one or more space filling panels 14. Thespace filling panel 14 may refer to one or more of the individual spacefilling panels 14 found in a vehicle such as a front left space fillingpanel 14 a, a front right space filling panel 14 b, a back left spacefilling panel 14 c, and a back right space filling panel 14 d (FIG. 2).The vehicle 10 may be any type of vehicle known to one skilled in theart. For example, the vehicle 10 may be a car, a truck, a minivan, acommercial vehicle, or any other type of consumer or commercial vehicle.

With reference to FIG. 2, the main cabin floor 38 is shown having thefront left space filling panel 14 a, the front right space filling panel14 b, the back left space filling panel 14 c, and the back right spacefilling panel 14 d provided thereon. However, it should be appreciatedthat the space filling panel 14 may be located in other areas of thevehicle that may have open voids or spaces to be filled. For example,the space filling panels 14 could be placed in a door, a quarter panel,a trunk, a storage compartment, a hood, a roof, or any other portion ofthe vehicle 10 where a reduction in NVH is desired and/or a space needsto be filled. The space filling panel 14 may be coupled into position byany number of non-limiting methods or devices such as, for example,attachment members, glue, additional paneling, and/or merely physicalplacement.

Referring now to FIGS. 3-4, the back right space filling panel 14 dshown is through an isometric view (FIG. 3) and a top view (FIG. 4). Theback right space filling panel 14 d has a top side 42, a bottom side 46,a side wall 50, a top edge 54, and a bottom edge 58. The polystyrenelayer 18 (FIG. 5) and the polyurethane layer 22 (FIG. 5) are completelyencapsulated in the vacuum sealed space 30 (FIG. 5) surrounded by thepolyethylene cover 26.

Referring now to FIG. 5, the polyurethane layer 22 is shown coupled tothe polystyrene layer 18 through a polyurethane surface geometry 66 anda polystyrene surface geometry 70. The polystyrene layer 18 and thepolyurethane layer 22 are positioned in the vacuum sealed space 30formed by the polyethylene cover 26. The polyethylene cover 26completely surrounds the polyurethane layer 22 and the polystyrene layer18 to keep the layers 18, 22 in place with respect to each other. In theembodiment shown in FIG. 5, there at least four layers shown going fromtop to bottom: the polyethylene cover 26, the polyurethane layer 22, thepolystyrene layer 18, and the polyethylene cover 26. In someembodiments, one or more polyurethane layers 22 may be coupled with oneor more polystyrene layers 18 in any combination or number. For example,there may be one polyurethane layer 22 coupled to two polystyrene layers18, two polyurethane layers 22 coupled to two polystyrene layers 18, twopolyurethane layers 22 coupled to three polystyrene layers 18, or threepolyurethane layers 22 coupled to four polystyrene layers 18. These samecombinations could be made with the polyurethane layers 22 and thepolystyrene layers 18 switched. In other embodiments, no adhesive orlubricant is applied or used between the polystyrene layers 18 andpolyurethane layers 22. The polyurethane and polystyrene surfacegeometries 66, 70 can include pyramidal, conical, channeled, or anyother geometry capable of interlocking or coupling with itself onopposing surfaces.

Referring now to FIG. 5A, the polyurethane layer 22 is shown coupled orsandwiched between two polystyrene layers 18 through the polyurethanesurface geometry 66 on the top and bottom sides of the polyurethanelayer 22 and the corresponding polystyrene surface geometries 70 on thepolystyrene layers 18. The polystyrene layers 18 and the polyurethanelayer 22 are positioned in the vacuum sealed space 30 formed by thepolyethylene cover 26. The polyethylene cover 26 completely surroundsthe polyurethane layer 22 and the polystyrene layers 18 to keep thelayers 18, 22 in place with respect to each other. In other embodiments,the polystyrene layer 18 may have the polystyrene surface geometry 70 onits top and bottom sides and can be sandwiched between two polyurethanelayers 22 and its corresponding polyurethane surface geometry 66 whereinthe three layers are then surrounded by the polyethylene cover 26forming the vacuum sealed space 30. The polyurethane and polystyrenesurface geometries 66, 70 can include pyramidal, conical, channeled, orany other geometry capable of interlocking or coupling with itself onopposing surfaces.

The polystyrene layer 18 may be produced from a variety of polystyrenesources including, but not limited to, for example, an expandedpolystyrene (EPS), a foam polystyrene, an extruded polystyrene foam,and/or styrene copolymers. In some embodiments, the polystyrene layer 18is an expanded polystyrene layer and has a density in the range of 1.35pcf to 1.80 pcf. The thickness of the polystyrene layer 18 used in thespace filling panel 14 may have a thickness of at least 8 mm, athickness of at least 15 mm, a thickness of at least 20 mm, or athickness of at least 30 mm. The polyurethane layer 22 may be producedfrom a variety of monomer sources not meant to be limiting, for example,a foam polyurethane, an extruded polyurethane foam, and/or a variety ofdifferent glycol urethane copolymers. The thickness of the polyurethanelayer 22 used in the space filling panel 14 may have a thickness of atleast 8 mm, a thickness of at least 15 mm, a thickness of at least 20mm, or a thickness of at least 30 mm. The thickness of the polystyrenelayer 18 and the polyurethane layer 22 may be the same or differentdepending on the desired application. In some embodiments, both thepolystyrene layer 18 and the polyurethane layer 22 may have a thicknessof at least 8 mm. In other embodiments, the polystyrene layer 18 mayhave a thickness of at least 15 mm and the polyurethane layer 22 have athickness of at least 8 mm. The polyethylene cover 26 used to create thevacuum sealed spaced 30 to position/encase the polystyrene layer 18 andthe polyurethane layer 22 may have a thickness of less than 15 mm, athickness of less than 10 mm, a thickness of less than 4 mm, a thicknessof less than 2 mm, and a thickness of less than 1 mm.

The vacuum sealed space 30 formed by the polyethylene cover 26 beingvacuum sealed around the polystyrene and polyurethane layers 18, 22 canbe made with any conventional or commercial vacuum packing machine. Insome embodiments, the vacuum of the vacuum sealed space 30 has apressure less than 1.0 atm, a pressure less than 0.5 atm, a pressureless than 0.1 atm, or a pressure less than 0.01 atm. When forming thevacuum sealed space 30, the pressure exerted on the polystyrene andpolyurethane layers 18, 22 preferably should not create more than a 10%compression, should not create more than a 5% compression, or should notcreate more than a 1% compression relative to the initial pre-compressedvolume of the polystyrene and polyurethane layers 18, 22.

Referring now to FIG. 6, the polystyrene layer 18 a has a plurality ofpolyurethane pieces or chips 62 embeddingly coupled in the polystyrenelayer 18 a. The polystyrene layer 18 a has the plurality of polyurethanechips 62 positioned in the vacuum sealed space 30 created by thepolyethylene cover 26. The plurality of polyurethane chips 62 may be inany size or shape and may be polydispersed across a variety of differentsizes and shapes. The plurality of polyurethane chips 62 may comprise atleast 5 wt %, at least 10 wt %, at least 15 wt %, at least 20 wt %, atleast 25 wt %, at least 30 wt %, at least 35 wt %, at least 40 wt %, atleast 45 wt %, at least 50 wt %, at least 55 wt %, at least 60 wt %, atleast 65 wt %, at least 70 wt %, or at least 75 wt % of the spacefilling panel 14. In some embodiments, the plurality of polyurethanechips 62 makes up at least 25 wt % of the space filling panel. In otherembodiments, the plurality of polyurethane chips 62 makes up at least 35wt % of the space filling panel. The plurality of polyurethane chips 62may be added to the polystyrene layer 18 a by any means known in theart.

Referring now to FIGS. 7-7A, the polystyrene layer 18 having apolystyrene pyramidal surface geometry 82 on a bottom surface 78 and thepolyurethane layer 22 having a polyurethane pyramidal surface geometry94 on a top surface 86 is shown. The polystyrene pyramidal surfacegeometry 82 and the polyurethane pyramidal surface geometry 94 arecomplementary to each other in that the pyramidal surface geometries 82,94 interconnect the polystyrene layer 18 and the polyurethane layer 22so that they do not slide or move laterally with respect to each other.The polystyrene pyramidal surface geometry 82 fits into the gaps of thepolyurethane pyramidal surface geometry 94 so there is a close couplingbetween the bottom surface 78 of the polystyrene layer 18 and the topsurface 86 of the polyurethane layer 22. FIG. 7A shows a side view ofthe interconnection or coupling of the pyramidal surface geometries 82,94 like a zipper between the bottom surface 78 and the top surface 86.In some embodiments, a polystyrene top surface 74 and a polyurethanebottom surface 90 may have additional surface geometries depending onthe application and the need for additional layers. In some embodiments,the polyurethane layer 22 and the polystyrene layer 18 each have atleast one surface with the pyramidal surface geometries 82, 94 thatinterlockedly couple the polyurethane layer 22 to the polystyrene layer18. In other embodiments, the polyurethane layer 22 and the polystyrenelayer 18 each have their top and bottom surfaces 86, 78 with thepyramidal surface geometries 82, 94 that interlockedly couple thepolyurethane layer 22 to the polystyrene layer 18.

Referring now to FIGS. 8-8A, the polystyrene layer 18 having apolystyrene cylindrical surface geometry 98 on the bottom side 78 of thepolystyrene layer 18 and the polyurethane layer 22 having thepolyurethane cylindrical surface geometry 102 on the top side 86 of thepolyurethane layer 22 is shown. The polystyrene cylindrical surfacegeometry 98 and the polyurethane cylindrical surface geometry 102 arecomplementary to each other in that the cylindrical surface geometries98, 102 interconnect the polystyrene layer 18 with the polyurethanelayer 22 so that they do not slide or move laterally with respect toeach other. The polystyrene cylindrical surface geometry 98 fits intothe gaps of the polyurethane cylindrical surface geometry 102 so thereis a close coupling between the bottom side 78 of the polystyrene layer18 and the top side 86 of the polyurethane layer 22. FIG. 8A shows aside view of the interconnection or interlocking of the cylindricalsurface geometries 98, 102 like a zipper between the bottom side 78 andthe top side 86. In some embodiments, the polyurethane layer 22 and thepolystyrene layer 18 each have at least one surface with the cylindricalsurface geometries 98, 102 that interlockedly couple the polyurethanelayer 22 to the polystyrene layer 18. In other embodiments, thepolyurethane layer 22 and the polystyrene layer 18 each have their topand bottom surfaces 86, 78 with the cylindrical surface geometries 98,102 that interlockedly couple the polyurethane layer 22 to thepolystyrene layer 18.

Referring now to FIGS. 9-9B, the polystyrene layer 18 having apolystyrene channeled surface geometry 106 on the bottom side 78 of thepolystyrene layer 18 and the polyurethane layer 22 having thepolyurethane channeled surface geometry 110 on the top side 86 of thepolyurethane layer 22 is shown. The polystyrene channeled surfacegeometry 106 and the polyurethane channeled surface geometry 110 arecomplementary to each other in that the channeled surface geometries106, 110 interconnect the polystyrene layer 18 with the polyurethanelayer 22 so that they do not slide or move laterally with respect toeach other. The polystyrene channeled surface geometry 106 fits into thegaps of the polyurethane channeled surface geometry 110 so there is aclose coupling between the bottom side 78 of the polystyrene layer 18and the top side 86 of the polyurethane layer 22. FIG. 9B shows a sideview of the interconnection or interlocking of the channeled surfacegeometries 106, 110 like a zipper between the bottom side 78 and the topside 86. In some embodiments, the polyurethane layer 22 and thepolystyrene layer 18 each have at least one surface with the channeledsurface geometries 106, 110 that interlockedly couple the polyurethanelayer 22 to the polystyrene layer 18. In other embodiments, thepolyurethane layer 22 and the polystyrene layer 18 each have their topand bottom surfaces 86, 78 with the channeled surface geometries 106,110 that interlockedly couple the polyurethane layer 22 to thepolystyrene layer 18.

A method for making the space filling panel 14 in the vehicle 10includes forming a first layer, forming a second layer, contacting afirst side of the first layer with a second side of the second layer,and vacuum sealing the first layer and the second layer with a polymericcover. The space filling panel is disposed in a cabin floor of thevehicle. The first layer and second layers may be any polymer material,for example, the polystyrene and polyurethane layers 18, 22 describedherein. The vacuum sealing can be formed with any gas impermeablepolymeric material, e.g. polyethylene, to form the vacuum sealed space30 as described herein. The first and second sides may additionally havesurface geometries 66, 70 as described by the description herein. Thismethod for making the space filling panel 14 can be combined with anyone or more of the intervening features described herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the disclosure as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structure without departing from the conceptsof the present invention, and further it is to be understood that suchconcepts are intended to be covered by the following claims unless theseclaims by their language expressly state otherwise.

What is claimed is:
 1. A space filling panel for a vehicle comprising: apolystyrene layer comprising a plurality of polyurethane chips; and apolyethylene cover forming a vacuum sealed space; wherein thepolystyrene layer comprising the plurality of polyurethane chips ispositioned in the vacuum sealed space.
 2. The space filling panel ofclaim 1, wherein the polystyrene layer is an expanded polystyrene layer.3. The space filling panel of claim 1, wherein the plurality ofpolyurethane chips are embeddingly coupled in the polystyrene layer. 4.The space filling panel of claim 1, wherein the plurality ofpolyurethane chips comprise at least 25 wt % of the space filling panel.5. The space filling panel of claim 1, wherein the plurality ofpolyurethane chips comprise at least 35 wt % of the space filling panel.6. The space filling panel of claim 1, wherein the vacuum sealed spacehas a pressure less than 1 atm.
 7. The space filling panel of claim 1,wherein the vacuum sealed space has a pressure less than 0.5 atm.
 8. Thespace filling panel of claim 1, wherein the polystyrene layer improvesthe space filling panel's NVH properties.
 9. A method for making a spacefilling panel in a vehicle comprising: forming a first layer having aplurality of polymer chips disposed within the first layer; and vacuumsealing the first layer with a polymeric cover to form the space fillingpanel; wherein the space filling panel is disposed in a cabin floor ofthe vehicle.
 10. The method of claim 9, wherein the polystyrene is anexpanded polystyrene layer.
 11. The method of claim 9, wherein theplurality of polymer chips comprise at least 25 wt % of the spacefilling panel.
 12. The method of claim 9, wherein the plurality ofpolymer chips comprise at least 35 wt % of the space filling panel. 13.The method of claim 9, wherein the space filling panel has a pressureless than 1 atm.
 14. The method of claim 9, wherein the space fillingpanel has a pressure less than 0.5 atm.
 15. The method of claim 9,wherein the first layer having the plurality of polymer chips improvesthe space filling panel's NVH properties.